Fuel cell module

ABSTRACT

A fuel cell module includes a first area where an exhaust gas combustor and a start-up combustor are provided, an annular second area around the first area and where a reformer and an evaporator are provided, and an annular third area around the second area and where a heat exchanger is provided. The exhaust gas combustor and the start-up combustor are provided coaxially with and separately away from each other.

TECHNICAL FIELD

The present invention relates to a fuel cell module including a fuel cell stack formed by stacking a plurality of fuel cells for generating electricity by electrochemical reactions of a fuel gas and an oxygen-containing gas.

BACKGROUND ART

Typically, a solid oxide fuel cell (SOFC) employs a solid electrolyte of ion-conductive solid oxide such as stabilized zirconia. The solid electrolyte is interposed between an anode and a cathode to form an electrolyte electrode assembly (hereinafter also referred to as MEA). The electrolyte electrode assembly is sandwiched between separators (bipolar plates). In use, generally, predetermined numbers of the electrolyte electrode assemblies and the separators are stacked together to form a fuel cell stack.

As a system including this type of fuel cell stack, for example, a fuel cell battery disclosed in Japanese Laid-Open Patent Publication No. 2001-236980 (hereinafter referred to as the conventional technique 1) is known. As shown in FIG. 10, the fuel cell battery includes a fuel cell stack 1 a, and a heat insulating sleeve 2 a is provided at one end of the fuel cell stack 1 a. A reaction device 4 a is provided in the heat insulating sleeve 2 a. The reaction device 4 a includes a heat exchanger 3 a.

In the reaction device 4 a, as a treatment of liquid fuel, partial oxidation reforming which does not use water is performed. After the liquid fuel is evaporated by an exhaust gas, the liquid fuel passes through a feeding point 5 a which is part of the heat exchanger 3 a. The fuel contacts an oxygen carrier gas heated by the exhaust gas thereby to induce partial oxidation reforming, and then, the fuel is supplied to the fuel cell stack 1 a.

Further, as shown in FIG. 11, a solid oxide fuel cell disclosed in Japanese Laid-Open Patent Publication No. 2010-504607 (PCT) (hereinafter referred to as the conventional technique 2) has a heat exchanger 2 b including a cell core 1 b. The heat exchanger 2 b heats the cathode air utilizing waste heat.

Further, as shown in FIG. 12, a fuel cell system disclosed in Japanese Laid-Open Patent Publication No. 2004-288434 (hereinafter referred to as the conventional technique 3) includes a first area is having a circular cylindrical shape extending vertically, and an annular second area 2 c around the first area 1 c, an annular third area 3 c around the second area 2 c, and an annular fourth area 4 c around the third area 3 c.

A burner 5 c is provided in the first area 1 c, and a reforming pipe 6 c is provided in the second area 2 c. A water evaporator 7 c is provided in the third area 3 c, and a CO shift converter 8 c is provided in the fourth area 4 c.

SUMMARY OF INVENTION

In the conventional technique 1, at the time of reforming by partial oxidation in the reaction device 4 a, heat of the exhaust gas is used for heating the liquid fuel and the oxygen carrier gas. Therefore, the quantity of heat for raising the temperature of the oxygen-containing gas supplied to the fuel cell stack 1 a tends to be inefficient, and the efficiency is low.

Further, in the conventional technique 2, in order to increase heat efficiency, long flow channels are adopted to have a sufficient heat transmission area. Therefore, considerably high pressure losses tend to occur.

Further, in the conventional technique 3, radiation of the heat from the central area having the highest temperature is suppressed using heat insulation material (partition wall). Therefore, heat cannot be recovered, and the efficiency is low.

The present invention has been made to solve the problems of this type, and an object of the present invention is to provide a fuel cell module having simple and compact structure in which it is possible to achieve improvement in the heat efficiency and facilitation of thermally self-sustaining operation.

The present invention relates to a fuel cell module including a fuel cell stack formed by stacking a plurality of fuel cells for generating electricity by electrochemical reactions of a fuel gas and an oxygen-containing gas, a reformer for reforming a mixed gas of a raw fuel chiefly containing hydrocarbon and water vapor to produce the fuel gas supplied to the fuel cell stack, an evaporator for evaporating water, and supplying the water vapor to the reformer, a heat exchanger for raising the temperature of the oxygen-containing gas by heat exchange with a combustion gas, and supplying the oxygen-containing gas to the fuel cell stack, an exhaust gas combustor for combusting the fuel gas discharged from the fuel cell stack as a fuel exhaust gas and the oxygen-containing gas discharged from the fuel cell stack as an oxygen-containing exhaust gas to produce the combustion gas, and a start-up combustor for combusting the raw fuel and the oxygen-containing gas to produce the combustion gas.

The fuel cell module includes a first area where the exhaust gas combustor and the start-up combustor are provided, an annular second area around the first area and where the reformer and the evaporator are provided, and an annular third area around the second area and where the heat exchanger is provided. Further, the exhaust gas combustor and the start-up combustor are provided coaxially with and separately away from each other. The exhaust gas combustor has a combustion cup member, and a combustion gas hole for supplying the combustion gas produced in the combustion cup member to the second area is formed in an outer circumferential portion of the combustion cup member.

In the present invention, the first area including the exhaust gas combustor and the start-up combustor is centrally-located. The annular second area is successively provided around the first area, and the annular third area is then provided around the second area. The reformer and the evaporator are provided in the second area, and the heat exchanger is provided in the third area.

In the structure, heat waste and heat radiation are suppressed suitably. Thus, improvement in the heat efficiency is achieved, and thermally self-sustaining operation is facilitated. Further, simple and compact structure is achieved in the entire fuel cell module. The thermally self-sustaining operation herein means operation where the operating temperature of the fuel cell is maintained using only heat energy generated by the fuel cell itself, without supplying additional heat from the outside.

Moreover, in the first area, the exhaust gas combustor and the start-up combustor are coaxially with and separated away from each other. Therefore, radiation of the heat of the combustion gas produced in the combustion cup member, due to heat dissipation toward the start-up combustor, is suppressed suitably. Accordingly, the exhaust gas combustor can sufficiently supply the heat to respective components in the second area and third area, i.e., the reformer, the evaporator, and the heat exchanger.

The above and other objects features and advantages of the present invention will become more apparent from the following description when taken in conjunction with the accompanying drawings in which a preferred embodiment of the present invention is shown by way of illustrative example.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 is a diagram schematically showing structure of a fuel cell system including a fuel cell module according to an embodiment of the present invention;

FIG. 2 is a perspective view showing FC peripheral equipment of the fuel cell module;

FIG. 3 is a cross sectional view showing the FC peripheral equipment;

FIG. 4 is a perspective view with partial omission showing the FC peripheral equipment;

FIG. 5 is an exploded perspective view showing main components of the FC peripheral equipment;

FIG. 6 is an exploded perspective view showing main components of an exhaust gas combustor of the FC peripheral equipment;

FIG. 7 is a cross sectional view showing the FC peripheral equipment;

FIG. 8 is a view showing an evaporation return pipe of the FC peripheral equipment;

FIG. 9 is another cross sectional view showing the FC peripheral equipment;

FIG. 10 is a view schematically showing a fuel cell battery disclosed in a conventional technique 1;

FIG. 11 is a perspective view with partial cutout showing a solid oxide fuel cell disclosed in a conventional technique 2; and

FIG. 12 is a view schematically showing a fuel cell system disclosed in a conventional technique 3.

DESCRIPTION OF EMBODIMENTS

As shown in FIG. 1, a fuel cell system 10 includes a fuel cell module 12 according to an embodiment of the present invention, and the fuel cell system 10 is used in various applications, including stationary and mobile applications. For example, the fuel cell system 10 is mounted on a vehicle.

The fuel cell system 10 includes the fuel cell module (SOFC module) 12 for generating electrical energy in power generation by electrochemical reactions of a fuel gas (a gas produced by mixing a hydrogen gas, methane, and carbon monoxide) and an oxygen-containing gas (air), a raw fuel supply apparatus (including a fuel gas pump) 14 for supplying a raw fuel (e.g., city gas) to the fuel cell module 12, an oxygen-containing gas supply apparatus (including an air pump) 16 for supplying the oxygen-containing gas to the fuel cell module 12, a water supply apparatus (including a water pump) 18 for supplying water to the fuel cell module 12, and a control device 20 for controlling the amount of electrical energy generated in the fuel cell module 12.

The fuel cell module 12 includes a solid oxide fuel cell stack 24 formed by stacking a plurality of solid oxide fuel cells 22 in a vertical direction (or horizontal direction). The fuel cell 22 includes an electrolyte electrode assembly (MEA) 32. The electrolyte electrode assembly 32 includes a cathode 28, an anode 30, and an electrolyte 26 interposed between the cathode 28 and the anode 30. For example, the electrolyte 26 is made of ion-conductive solid oxide such as stabilized zirconia.

A cathode side separator 34 and an anode side separator 36 are provided on both sides of the electrolyte electrode assembly 32. An oxygen-containing gas flow field 38 for supplying the oxygen-containing gas to the cathode 28 is formed in the cathode side separator 34, and a fuel gas flow field 40 for supplying the fuel gas to the anode 30 is formed in the anode side separator 36. As the fuel cell 22, various types of conventional SOFCs can be adopted.

The operating temperature of the fuel cell 22 is high, that is, several hundred ° C. Methane in the fuel gas is reformed at the anode 30 to obtain hydrogen and CO, and the hydrogen and CO are supplied to a portion of the electrolyte 26 adjacent to the anode 30.

An oxygen-containing gas supply passage 42 a, an oxygen-containing gas discharge passage 42 b, a fuel gas supply passage 44 a, and a fuel gas discharge passage 44 b extend through the fuel cell stack 24. The oxygen-containing gas supply passage 42 a is connected to an inlet of each oxygen-containing gas flow field 38, the oxygen-containing gas discharge passage 42 b is connected to an outlet of each oxygen-containing gas flow field 38, the fuel gas supply passage 44 a is connected to an inlet of each fuel gas flow field 40, and the fuel gas discharge passage 44 b is connected to an outlet of each fuel gas flow field 40.

The fuel cell module 12 includes a reformer 46 for reforming a mixed gas of a raw fuel chiefly containing hydrocarbon (e.g., city gas) and water vapor to produce a fuel gas supplied to the fuel cell stack 24, an evaporator 48 for evaporating water and supplying the water vapor to the reformer 46, a heat exchanger 50 for raising the temperature of the oxygen-containing gas by heat exchange with a combustion gas, and supplying the oxygen-containing gas to the fuel cell stack 24, an exhaust gas combustor 52 for combusting the fuel gas discharged from the fuel cell stack 24 as a fuel exhaust gas and the oxygen-containing gas discharged from the fuel cell stack 24 as an oxygen-containing exhaust gas to produce the combustion gas, and a start-up combustor 54 for combusting the raw fuel and the oxygen-containing gas to produce the combustion gas.

Basically, the fuel cell module 12 is made up of the fuel cell stack 24 and FC (fuel cell) peripheral equipment (BOP) 56 (see FIGS. 1 and 2). The FC peripheral equipment 56 includes the reformer 46, the evaporator 48, the heat exchanger 50, the exhaust gas combustor 52, and the start-up combustor 54.

As shown in FIGS. 3 to 5, the FC peripheral equipment 56 includes a first area R1 where the exhaust gas combustor 52 and the start-up combustor 54 are provided, an annular second area R2 formed around the first area R1 and where the reformer 46 and the evaporator 48 are provided, an annular third area R3 formed around the second area R2 and where the heat exchanger 50 is provided. A cylindrical outer member 55 constituting an outer wall is provided on the outer peripheral side of the third area R3.

The start-up combustor 54 is provided at the other end distant from the fuel cell stack 24, and includes an air supply pipe 57 and a raw fuel supply pipe 58. The start-up combustor 54 has an ejector function, and generates negative pressure in the raw fuel supply pipe 58 by the flow of the air supplied from the air supply pipe 57 for sucking the raw fuel.

The exhaust gas combustor 52 is provided at one end adjacent to the fuel cell stack 24, and has a combustion cup member 60 at a position spaced away from the start-up combustor 54. The combustion cup member 60 includes a support portion 61 and a cup portion 62 attached to the support portion 61 in an orientation from the fuel cell stack 24 toward the start-up combustor 54 (first area R1).

The support portion 61 includes an attachment plate body 61 a to which the fuel cell stack 24 is attached, and a cylindrical body 61 b formed integrally with the attachment plate body 61 a. A plurality of holes (e.g., circular holes or rectangular holes) 62 a, which are combustion gas holes, are formed along the outer circumference of the marginal end of the cup portion 62 on the bottom side. The bottom surface 62 e of the cup portion 62 is set at a position spaced away from (deviated from) an intermediate position h (see FIG. 3) in the axial direction (indicated by an arrow L) of the FC peripheral equipment 56 toward the fuel cell stack 24. Alternatively, the bottom surface 62 e of the cup portion 62 may be set at a position spaced away from the intermediate position h (see FIG. 3) in the axial direction of the FC peripheral equipment away from the fuel cell stack 24.

The combustion cup member 60 has a fixing mechanism 64 for fixing the support portion 61 and the cup portion 62 together such that the support portion 61 and the cup portion 62 are not rotatable with respect to each other. As shown in FIG. 6, the fixing mechanism 64 includes recesses 64 b and a protrusion 64 a that is engageable with any of the recesses 64 b. The protrusion 64 a is formed at the other end of the cup portion 62, which is an open end, so as to protrude radially outwardly. The recesses 64 b are formed at a lip portion of the inner circumferential surface of the support portion 61.

For the purpose of adjusting the phase between the support portion 61 and the cup portion 62, at least the recesses 64 b are provided at a plurality of, e.g., two positions. The protrusion 64 a may be provided in the support portion 61, and the recesses 64 b may be provided in the cup portion 62.

One end of an oxygen-containing exhaust gas channel 63 a and one end of a fuel exhaust gas channel 63 b are provided at the combustion cup member 60. The combustion gas is produced inside the combustion cup member 60 by combustion reaction of the fuel gas (more specifically, fuel exhaust gas) and the oxygen-containing gas (more specifically, oxygen-containing exhaust gas).

As shown in FIG. 1, the other end of the oxygen-containing exhaust gas channel 63 a is connected to the oxygen-containing gas discharge passage 42 b of the fuel cell stack 24, and the other end of the fuel exhaust gas channel 63 b is connected to the fuel gas discharge passage 44 b of the fuel cell stack 24.

As shown in FIGS. 3 to 5, the reformer 46 is a preliminary reformer for reforming higher hydrocarbon (C₂₊) such as ethane (C₂H₆), propane (C₃H₈), and butane (C₄H₁₀) in the city gas (raw fuel) to produce the fuel gas chiefly containing methane (CH₄), hydrogen, and CO by steam reforming. The operating temperature of the reformer 46 is set at several hundred ° C.

The reformer 46 includes a plurality of reforming pipes (heat transmission pipes) 66 provided around the exhaust gas combustor 52 and the start-up combustor 54. Each of the reforming pipes 66 is filled with reforming catalyst pellets (not shown). Each of the reforming pipes 66 has one end (lower end) fixed to a first lower ring member 68 a, and the other end (upper end) fixed to a first upper ring member 68 b.

The outer circumferential portions of the first lower ring member 68 a and the first upper ring member 68 b are fixed to the inner circumferential surface of a cylindrical member 70 by welding or the like. The inner circumferential portions of the first lower ring member 68 a and the first upper ring member 68 b are fixed to the outer circumferential portions of the exhaust gas combustor 52 and the start-up combustor 54 by welding or the like. The cylindrical member 70 extends in an axial direction indicated by an arrow L, and an end of the cylindrical member 70 adjacent to the fuel cell stack 24 is fixed to the attachment plate body 61 a. A plurality of openings 72 are formed in the outer circumference of the cylindrical member 70 in a circumferential direction at predetermined height positions.

The evaporator 48 has evaporation pipes (heat transmission pipes) 74 provided adjacent to, and outside the reforming pipes 66 of the reformer 46. As shown in FIG. 7, the reforming pipes 66 are arranged at equal intervals on a virtual circle, concentrically around the first area R1. The evaporation pipes 74 are arranged at equal intervals on a virtual circle, concentrically around the first area R1. The number of the evaporation pipes 74 is half of the number of the reforming pipes 66. The evaporation pipes 74 are positioned on the back side of every other position of the reforming pipe 66 (i.e., at positions spaced away from the center of the first area R1).

As shown in FIGS. 3 and 4, each of the evaporation pipes 74 has one end (lower end) which is fixed to a second lower ring member 76 a by welding or the like, and the other end (upper end) which is fixed to a second upper ring member 76 b by welding or the like. The outer circumferential portions of the second lower ring member 76 a and the second upper ring member 76 b are fixed to the inner circumferential surface of the cylindrical member 70 by welding or the like. The inner circumferential portions of the second lower ring member 76 a and the second upper ring member 76 b are fixed to the outer circumferential portions of the exhaust gas combustor 52 and the start-up combustor 54 by welding or the like.

The second lower ring member 76 a is positioned below the first lower ring member 68 a (i.e., outside the first lower ring member 68 a in the axial direction), and the second upper ring member 76 b is positioned above the first upper ring member 68 b (i.e., outside the first upper ring member 68 b in the axial direction).

An annular mixed gas supply chamber 78 a is formed between the first lower ring member 68 a and the second lower ring member 76 a, and a mixed gas of raw fuel and water vapor is supplied to the mixed gas supply chamber 78 a. Further, an annular fuel gas discharge chamber 78 b is formed between the first upper ring member 68 b and the second upper ring member 76 b, and the produced fuel gas (reformed gas) is discharged to the fuel gas discharge chamber 78 b. Both ends of each of the reforming pipes 66 are opened to the mixed gas supply chamber 78 a and the fuel gas discharge chamber 78 b.

A ring shaped end ring member 80 is fixed to an end of the cylindrical member 70 on the start-up combustor 54 side by welding or the like. An annular water supply chamber 82 a is formed between the end ring member 80 and the second lower ring member 76 a, and water is supplied to the water supply chamber 82 a. An annular water vapor discharge chamber 82 b is formed between the second upper ring member 76 b and the attachment plate body 61 a, and water vapor is discharged to the water vapor discharge chamber 82 b. Both ends of each of the evaporation pipes 74 are opened to the water supply chamber 82 a and the water vapor discharge chamber 82 b.

The fuel gas discharge chamber 78 b and the water vapor discharge chamber 82 b are provided in a double deck manner, and the fuel gas discharge chamber 78 b is provided on the inner side with respect to the water vapor discharge chamber 82 b (i.e., below the water vapor discharge chamber 82 b). The mixed gas supply chamber 78 a and the water supply chamber 82 a are provided in a double deck manner, and the mixed gas supply chamber 78 a is provided on the inner side with respect to the water supply chamber 82 a (i.e., above the water supply chamber 82 a).

A raw fuel supply channel 84 is opened to the mixed gas supply chamber 78 a, and an evaporation return pipe 90 described later is connected to a position in the middle of the raw fuel supply channel 84 (see FIG. 1). The raw fuel supply channel 84 has an ejector function, and generates negative pressure by the flow of the raw fuel for sucking the water vapor.

The raw fuel supply channel 84 is fixed to the second lower ring member 76 a and the end ring member 80 by welding or the like. One end of a fuel gas channel 86 is connected to the fuel gas discharge chamber 78 b, and the other end of the fuel gas channel 86 is connected to the fuel gas supply passage 44 a of the fuel cell stack 24 (see FIG. 1). The fuel gas channel 86 is fixed to the second upper ring member 76 b by welding or the like, and extends through the attachment plate body 61 a (see FIG. 2).

A water channel 88 is connected to the water supply chamber 82 a. The water channel 88 is fixed to the end ring member 80 by welding or the like. One end of the evaporation return pipe 90 formed by at least one evaporation pipe 74 is provided in the water vapor discharge chamber 82 b, and the other end of the evaporation return pipe 90 is connected to a position in the middle of the raw fuel supply channel 84 (see FIG. 1).

As shown in FIG. 8, the evaporation return pipe 90 has dual pipe structure 92 in a portion thereof passing through the mixed gas supply chamber 78 a and the water supply chamber 82 a. The dual pipe structure 92 includes an outer pipe 94. The outer pipe 94 surrounds the evaporation return pipe 90, and the outer pipe 94 is positioned coaxially with the evaporation return pipe 90. The outer pipe 94 is fixed to the first lower ring member 68 a, the second lower ring member 76 a, and the end ring member 80 by welding or the like, and extends in the direction indicated by an arrow L. A gap is provided between the outer circumference of the evaporation return pipe 90 and the inner circumference of the outer pipe 94. This gap may not be provided.

The evaporation return pipe 90 may have dual pipe structure 92 a in a portion thereof passing through the fuel gas discharge chamber 78 b. The dual pipe structure 92 a includes an outer pipe 94 a. The outer pipe 94 a surrounds the evaporation return pipe 90, and the outer pipe 94 a is positioned coaxially with the evaporation return pipe 90. The outer pipe 94 a is fixed to the first upper ring member 68 b and the second upper ring member 76 b by welding or the like, and extends in the direction indicated by the arrow L. A gap is formed between the outer circumference of the evaporation return pipe 90 and the inner circumference of the outer pipe 94 a as necessary. The lower end of the outer pipe 94 a is not welded to the first upper ring member 68 b.

As shown in FIGS. 3 and 4, the heat exchanger 50 includes a plurality of heat exchange pipes (heat transmission pipes) 96 which are provided along and around the outer circumference of the cylindrical member 70. Each of the heat exchange pipes 96 has one end (lower end) fixed to a lower ring member 98 a, and the other end (upper end) fixed to an upper ring member 98 b.

A lower end ring member 100 a is provided below the lower ring member 98 a, and an upper end ring member 100 b is provided above the upper ring member 98 b. The lower end ring member 100 a and the upper end ring member 100 b are fixed to the outer circumference of the cylindrical member 70 and the inner circumference of the outer member 55 by welding or the like.

An annular oxygen-containing gas supply chamber 102 a to which the oxygen-containing gas is supplied is formed between the lower ring member 98 a and the lower end ring member 100 a. An annular oxygen-containing gas discharge chamber 102 b is formed between the upper ring member 98 b and the upper end ring member 100 b. The heated oxygen-containing gas is discharged to the oxygen-containing gas discharge chamber 102 b. Both ends of each of the heat exchange pipes 96 are fixed to the lower ring member 98 a and the upper ring member 98 b by welding or the like, and opened to the oxygen-containing gas supply chamber 102 a and the oxygen-containing gas discharge chamber 102 b.

The mixed gas supply chamber 78 a and the water supply chamber 82 a are placed on the radially inward side relative to the inner circumference of the oxygen-containing gas supply chamber 102 a. The oxygen-containing gas discharge chamber 102 b is provided outside the fuel gas discharge chamber 78 b at a position offset downward from the fuel gas discharge chamber 78 b.

A cylindrical cover member 104 is provided on the outer circumferential portion of the outer member 55. The center of the cylindrical cover member 104 is shifted downward. Both of upper and lower ends (both of axial ends) of the cover member 104 are fixed to the outer member 55 by welding or the like, and a heat recovery area (chamber) 106 is formed between the cover member 104 and the outer circumferential surface of the outer member 55.

A plurality of holes 108 are formed circumferentially in a lower marginal end portion of the outer member 55 of the oxygen-containing gas supply chamber 102 a, and the oxygen-containing gas supply chamber 102 a communicates with the heat recovery area 106 through the holes 108. An oxygen-containing gas supply pipe 110 communicating with the heat recovery area 106 is connected to the cover member 104. An exhaust gas pipe 112 communicating with the third area R3 is connected to an upper portion of the outer member 55.

For example, one end of each of two oxygen-containing gas pipes 114 is provided in the oxygen-containing gas discharge chamber 102 b. Each of the oxygen-containing gas pipes 114 has a stretchable member such as a bellows 114 a between the upper end ring member 100 b and the attachment plate body 61 a. The other end of each of the oxygen-containing gas pipes 114 extends through the attachment plate body 61 a, and is connected to the oxygen-containing gas supply passage 42 a of the fuel cell stack 24 (see FIG. 1).

As shown in FIG. 3, a first combustion gas channel 116 a as a passage of the combustion gas is formed in the first area R1, and a second combustion gas channel 116 b as a passage of the combustion gas that has passed through the holes 62 a is formed in the second area R2. A third combustion gas channel 116 c as a passage of the combustion gas that has passed through the openings 72 is formed in the third area R3. Further, a fourth combustion gas channel 116 d is formed as a passage after the exhaust gas pipe 112. The second combustion gas channel 116 b forms the reformer 46 and the evaporator 48, and the third combustion gas channel 116 c forms the heat exchanger 50.

As shown in FIG. 1, the raw fuel supply apparatus 14 includes a raw fuel channel 118. The raw fuel channel 118 is branched into the raw fuel supply channel 84 and the raw fuel supply pipe 58 through a raw fuel regulator valve 120. A desulfurizer 122 for removing sulfur compounds in the city gas (raw fuel) is provided in the raw fuel supply channel 84.

The oxygen-containing gas supply apparatus 16 includes an oxygen-containing gas channel 124. The oxygen-containing gas channel 124 is branched into the oxygen-containing gas supply pipe 110 and the air supply pipe 57 through an oxygen-containing gas regulator valve 126. The water supply apparatus 18 is connected to the evaporator 48 through the water channel 88.

Operation of the fuel cell system 10 will be described below.

At the time of starting operation of the fuel cell system 10, the air (oxygen-containing gas) and the raw fuel are supplied to the start-up combustor 54. More specifically, by operation of the air pump, the air is supplied to the oxygen-containing gas channel 124. By adjusting the opening degree of the oxygen-containing gas regulator valve 126, the air is supplied to the air supply pipe 57.

In the meanwhile, in the raw fuel supply apparatus 14, by operation of the fuel gas pump, for example, raw fuel such as the city gas (containing CH₄, C₂H₆, C₃H₈, C₄H₁₀) is supplied to the raw fuel channel 118. By regulating the opening degree of the raw fuel regulator valve 120, the raw fuel is supplied into the raw fuel supply pipe 58. The raw fuel is mixed with the air, and supplied into the start-up combustor 54 (see FIGS. 3 and 4).

Thus, the mixed gas of the raw fuel and the air is supplied into the start-up combustor 54, and the mixed gas is ignited to start combustion. Therefore, the combustion gas produced in combustion flows from the first area R1 to the second area R2. Further, the combustion gas is supplied to the third area R3, and then, the combustion gas is discharged to the outside of the fuel cell module 12 through the exhaust gas pipe 112.

As shown in FIGS. 3 and 4, the reformer 46 and the evaporator 48 are provided in the second area R2, and the heat exchanger 50 is provided in the third area R3. Thus, the combustion gas discharged from the first area R1 first heats the reformer 46, next heats the evaporator 48, and then heats the heat exchanger 50.

Then, after the temperature of the fuel cell module 12 is raised to a predetermined temperature, the air (oxygen-containing gas) is supplied to the heat exchanger 50, and the mixed gas of the raw fuel and the water vapor is supplied to the reformer 46.

More specifically, as shown in FIG. 1, the opening degree of the oxygen-containing gas regulator valve 126 is adjusted such that the flow rate of the air supplied to the oxygen-containing gas supply pipe 110 is increased, and the opening degree of the raw fuel regulator valve 120 is adjusted such that the flow rate of the raw fuel supplied to the raw fuel supply channel 84 is increased. Further, by operation of the water supply apparatus 18, the water is supplied to the water channel 88. The air is supplied from the oxygen-containing gas supply pipe 110 to the heat recovery area 106 of the outer member 55. Thus, the air flows through the holes 108 into the oxygen-containing gas supply chamber 102 a.

Therefore, as shown in FIGS. 3 and 4, the air flows into the heat exchanger 50, and the air is temporarily supplied to the oxygen-containing gas supply chamber 102 a. Thereafter, while the air is moving inside the heat exchange pipes 96, the air is heated by heat exchange with the combustion gas supplied into the third area R3. After the heated air is temporarily supplied to the oxygen-containing gas discharge chamber 102 b, the air is supplied to the oxygen-containing gas supply passage 42 a of the fuel cell stack 24 through the oxygen-containing gas pipes 114 (see FIG. 1). In the fuel cell stack 24, the heated air flows along the oxygen-containing gas flow field 38, and the air is supplied to the cathode 28.

After the air flows through the oxygen-containing gas flow field 38, the air is discharged from the oxygen-containing gas discharge passage 42 b into the oxygen-containing exhaust gas channel 63 a. The oxygen-containing exhaust gas channel 63 a is opened to the combustion cup member 60 of the exhaust gas combustor 52, and the oxygen-containing exhaust gas is supplied into the cup portion 62 of the combustion cup member 60.

Further, as shown in FIG. 1, the water from the water supply apparatus 18 is supplied to the evaporator 48. After the raw fuel is desulfurized in the desulfurizer 122, the raw fuel flows through the raw fuel supply channel 84, and moves toward the reformer 46.

In the evaporator 48, after the water is temporarily supplied to the water supply chamber 82 a, while water is moving inside the evaporation pipes 74, the water is heated by the combustion gas flowing through the second area R2, and vaporized. After the water vapor flows into the water vapor discharge chamber 82 b, the water vapor is supplied to the evaporation return pipe 90 connected to the water vapor discharge chamber 82 b. Thus, the water vapor flows inside the evaporation return pipe 90, and flows into the raw fuel supply channel 84. Then, the water vapor is mixed with the raw fuel supplied by the raw fuel supply apparatus 14 to produce the mixed gas.

The mixed gas from the raw fuel supply channel 84 is temporarily supplied to the mixed gas supply chamber 78 a of the reformer 46. The mixed gas moves inside the reforming pipes 66. In the meanwhile, the mixed gas is heated by the combustion gas flowing through the second area R2, and is then steam-reformed. After removal (reforming) of hydrocarbon of C₂₊, a reformed gas chiefly containing methane is obtained.

After this reformed gas is heated, the reformed gas is temporarily supplied to the fuel gas discharge chamber 78 b as the fuel gas. Thereafter, the fuel gas is supplied to the fuel gas supply passage 44 a of the fuel cell stack 24 through the fuel gas channel 86 (see FIG. 1). In the fuel cell stack 24, the heated fuel gas flows along the fuel gas flow field 40, and the fuel gas is supplied to the anode 30. In the meanwhile, the air is supplied to the cathode 28. Thus, electricity is generated in the electrolyte electrode assembly 32.

After the fuel gas flows through the fuel gas flow field 40, the fuel gas is discharged from the fuel gas discharge passage 44 b to the fuel exhaust gas channel 63 b. The fuel exhaust gas channel 63 b is opened to the inside of the combustion cup member 60 of the exhaust gas combustor 52, and the fuel exhaust gas is supplied into the cup portion 62 of the combustion cup member 60.

Under the heating operation by the start-up combustor 54, when the temperature of the fuel gas in the exhaust gas combustor 52 exceeds the self-ignition temperature, combustion of the oxygen-containing exhaust gas and the fuel exhaust gas is started inside the cup portion 62. In the meanwhile, combustion operation by the start-up combustor 54 is stopped.

The holes 62 a are formed in the cup portion 62. Therefore, the combustion gas supplied into the cup portion 62 passes through the holes 62 a, and flows from the first area R1 into the second area R2. Then, after the combustion gas is supplied to the third area R3, the combustion gas is discharged to the outside of the fuel cell module 12.

In the present embodiment, the FC peripheral equipment 56 includes the first area R1 where the exhaust gas combustor 52 and the start-up combustor 54 are provided, the annular second area R2 around the first area R1 and where the reformer 46 and the evaporator 48 are provided, and the annular third area R3 around the second area R2 and where the heat exchanger 50 is provided.

That is, the first area R1 is provided at the center, the annular second area R2 is provided around the first area R1, and the annular third area R3 is provided around the second area R2. Heat waste and heat radiation can be suppressed suitably. Thus, improvement in the heat efficiency is achieved, thermally self-sustaining operation is facilitated, and simple and compact structure of the entire fuel cell module 12 is achieved. Thermally self-sustaining operation herein means operation where the operating temperature of the fuel cell 22 is maintained using only heat energy generated in the fuel cell 22 itself, without supplying additional heat from the outside.

Moreover, in the first area R1, the exhaust gas combustor 52 and the start-up combustor 54 are coaxially with and separated away from each other. Therefore, heat radiation of the combustion gas produced in the combustion cup member 60, due to heat dissipation toward the start-up combustor 54, is suppressed suitably. Accordingly, the exhaust gas combustor 52 can sufficiently supply the heat to respective components in the second area R2 and the third area R3, i.e., the reformer 46, the evaporator 48, and the heat exchanger 50.

Further, in the present embodiment, as shown in FIG. 3, the reformer 46 includes the annular mixed gas supply chamber 78 a, the annular fuel gas discharge chamber 78 b, the reforming pipes 66, and the second combustion gas channel 116 b. The mixed gas is supplied to the mixed gas supply chamber 78 a, and the produced fuel gas is discharged into the fuel gas discharge chamber 78 b. Each of the reforming pipes 66 has one end connected to the mixed gas supply chamber 78 a, and the other end connected to the fuel gas discharge chamber 78 b. The second combustion gas channel 116 b supplies the combustion gas to the space between the reforming pipes 66.

The evaporator 48 includes the annular water supply chamber 82 a, the annular water vapor discharge chamber 82 b, the evaporation pipes 74, and the second combustion gas channel 116 b. The water is supplied to the water supply chamber 82 a, and the water vapor is discharged into the water vapor discharge chamber 82 b. Each of the evaporation pipes 74 has one end connected to the water supply chamber 82 a, and the other end connected to the water vapor discharge chamber 82 b. The second combustion gas channel 116 b supplies the combustion gas to the space between the evaporation pipes 74.

The heat exchanger 50 includes the annular oxygen-containing gas supply chamber 102 a, the annular oxygen-containing gas discharge chamber 102 b, the heat exchange pipes 96, and the third combustion gas channel 116 c. The oxygen-containing gas is supplied to the oxygen-containing gas supply chamber 102 a, and the heated oxygen-containing gas is discharged into the oxygen-containing gas discharge chamber 102 b. Each of the heat exchange pipes 96 has one end connected to the oxygen-containing gas supply chamber 102 a, and the other end connected to the oxygen-containing gas discharge chamber 102 b. The third combustion gas channel 116 c supplies the combustion gas to the space between the heat exchange pipes 96.

As described above, the annular supply chambers (mixed gas supply chamber 78 a, water supply chamber 82 a, and oxygen-containing gas supply chamber 102 a), the annular discharge chambers (fuel gas discharge chamber 78 b, water vapor discharge chamber 82 b, and oxygen-containing gas discharge chamber 102 b) and the pipes (reforming pipes 66, evaporation pipes 74, and heat exchange pipes 96) are provided as basic structure. Thus, simple structure is achieved easily. Accordingly, the production cost of the fuel cell module 12 is reduced effectively. Further, by changing the volumes of the supply chambers and the discharge chambers, and the length, the diameter, and the number of the pipes, a suitable operation can be achieved depending on various operating conditions, and the design flexibility of the fuel cell module can be enhanced.

Further, the fuel gas discharge chamber 78 b, the water vapor discharge chamber 82 b, and the oxygen-containing gas discharge chamber 102 b are provided at the side of one end adjacent to the fuel cell stack 24, and the mixed gas supply chamber 78 a, the water supply chamber 82 a, and the oxygen-containing gas supply chamber 102 a are provided at the side of the other end distant from the fuel cell stack 24.

In the structure, the reactant gas immediately after heating and the reactant gas immediately after reforming (fuel gas and oxygen-containing gas) can be supplied to the fuel cell stack 24 promptly. Further, the exhaust gas from the fuel cell stack 24 can be supplied to the exhaust gas combustor 52, the reformer 46, the evaporator 48, and the heat exchanger 50 of the FC peripheral equipment 56 while decrease in the temperature of the exhaust gas from the fuel cell stack 24 due to heat radiation is suppressed as much as possible. Thus, improvement in the heat efficiency is achieved, and thermally self-sustaining operation is facilitated.

Further, the exhaust gas combustor 52 is provided at the side of one end adjacent to the fuel cell stack 24, and the start-up combustor 54 is provided at the side of the other end distant from the fuel cell stack 24. In the structure, when the exhaust gas from the fuel cell stack 24 is supplied to the exhaust gas combustor 52, and combusted to produce a combustion gas, decrease in the temperature is suppressed as much as possible. Therefore, improvement in the heat efficiency is achieved, and thermally self-sustaining operation is facilitated easily.

Further, since the start-up combustor 54 supplies the combustion gas toward the fuel cell stack 24, the time required for increasing the temperature of the fuel cell stack 24, i.e., the time required for starting operation, can be reduced effectively.

Further, as shown in FIG. 3, the bottom surface 62 e of the combustion cup member 60 is provided at the position deviated from the intermediate position h of the first area R1 toward the fuel cell stack 24. In the structure, the combustion gas maintained at a high temperature can be reliably supplied to the reformer 46 and the evaporator 48 in the second area R2.

Alternatively, the bottom surface 62 e of the combustion cup member 60 may be provided at the position deviated from the intermediate position h of the first area R1 away from the fuel cell stack 24. In the structure, the combustion gas can be distributed suitably over the entire reformer 46 and the entire evaporator 48 provided in the second area R2.

Further, as shown in FIGS. 3, 4, and 6, the combustion cup member 60 includes the support portion 61 fixed to the first area R1, and the cup portion 62 attached to the support portion 61 in an orientation from the fuel cell stack 24 toward the first area R1. Thus, the structure of the combustion cup member 60 is simplified, and reduction in the number of assembling steps is achieved.

Further, as shown in FIG. 6, the combustion cup member 60 has the fixing mechanism 64 for fixing the support portion 61 and the cup portion 62 together such that the support portion 61 and the cup portion 62 are not rotatable with respect to each other. The fixing mechanism 64 includes the recesses 64 b and the protrusion 64 a that is engageable with any of the recesses 64 b. At least the recesses 64 b are provided at a plurality of positions, e.g., at two positions for enabling adjustment of the phase between the support portion 61 and the cup portion 62.

Therefore, simply by providing and arranging the protrusion 64 a and the recesses 64 b, the phase of the holes 62 a can be adjusted. That is, in FIG. 7, the holes 62 a are oriented toward positions between the reforming pipes 66 of the reformer 46. Since the combustion gas supplied from the holes 62 a to the second area R2 flows toward the positions between the reforming pipes 66, the quantity of the heat supplied to the reforming pipes 66 is relatively small. Thus, the heat exchanging efficiency of the reformer 46 is low.

In contrast, in FIG. 9, the holes 62 a are oriented toward the reforming pipes 66 of the reformer 46. Since the combustion gas supplied from the holes 62 a to the second area R2 flows toward the reforming pipes 66, the quantity of heat supplied to the reforming pipes 66 is relatively large. Therefore, improvement in the heat exchanging efficiency in the reformer 46 is achieved. Thus, the quantity of the heat supplied to respective components, in particular the reformer 46, can be adjusted easily and reliably.

Further, as shown in FIG. 3, the combustion gas flows from the first area R1 to the second area R2, and then, flows from the second area R2 to the third area R3. Thereafter, the combustion gas is discharged to the outside of the fuel cell module 12. In the structure, the heat can be effectively supplied to the exhaust gas combustor 52, the reformer 46, the evaporator 48, and the heat exchanger 50 of the FC peripheral equipment 56. Thus, improvement in the heat efficiency is achieved, and thermally self-sustaining operation is facilitated.

Further, the fuel cell module 12 is a solid oxide fuel cell module. Therefore, the fuel cell module 12 is suitable for, in particular, high temperature type fuel cells such as SOFC.

While the invention has been particularly shown and described with reference to a preferred embodiment, it will be understood that variations and modifications can be effected thereto by those skilled in the art without departing from the scope of the invention as defined by the appended claims. 

The invention claimed is:
 1. A fuel cell module comprising: a fuel cell stack formed by stacking a plurality of fuel cells for generating electricity by electrochemical reactions of a fuel gas and an oxygen-containing gas; a reformer for reforming a mixed gas of a raw fuel chiefly containing hydrocarbon and water vapor to produce the fuel gas supplied to the fuel cell stack; an evaporator for evaporating water, and supplying the water vapor to the reformer, a heat exchanger for raising a temperature of the oxygen-containing gas by heat exchange with a combustion gas, and supplying the oxygen-containing gas to the fuel cell stack; an exhaust gas combustor for combusting the fuel gas discharged from the fuel cell stack as a fuel exhaust gas and the oxygen-containing gas discharged from the fuel cell stack as an oxygen-containing exhaust gas to produce the combustion gas; and a start-up combustor for combusting the raw fuel and the oxygen-containing gas to produce the combustion gas, wherein the fuel cell module includes: a first area where the exhaust gas combustor and the start-up combustor are provided; an annular second area around the first area and where the reformer and the evaporator are provided; and an annular third area around the second area and where the heat exchanger is provided; and wherein the exhaust gas combustor and the start-up combustor are provided coaxially with and separately away from each other; and the exhaust gas combustor has a combustion cup member, and a combustion gas hole for supplying the combustion gas produced in the combustion cup member to the second area is formed in an outer circumferential portion of the combustion cup member.
 2. The fuel cell module according to claim 1, wherein the reformer includes an annular mixed gas supply chamber to which the mixed gas is supplied, an annular fuel gas discharge chamber to which the produced fuel gas is discharged, a plurality of reforming pipes each having one end connected to the mixed gas supply chamber, and another end connected to the fuel gas discharge chamber, and a combustion gas channel for supplying the combustion gas to spaces between the reforming pipes; the evaporator includes an annular water supply chamber to which the water is supplied, an annular water vapor discharge chamber to which the water vapor is discharged, a plurality of evaporation pipes each having one end connected to the water supply chamber, and another end connected to the water vapor discharge chamber and a combustion gas channel for supplying the combustion gas to spaces between the evaporation pipes; and the heat exchanger includes an annular oxygen-containing gas supply chamber to which the oxygen-containing gas is supplied, an annular oxygen-containing gas discharge chamber to which the heated oxygen-containing gas is discharged, a plurality of heat exchange pipes each having one end connected to the oxygen-containing gas supply chamber, and another end connected to the oxygen-containing gas discharge chamber, and a combustion gas channel for supplying the combustion gas to spaces between the heat exchange pipes.
 3. The fuel cell module according to claim 2, wherein the fuel gas discharge chamber, the water vapor discharge chamber, and the oxygen-containing gas discharge chamber are provided at one end side adjacent to the fuel cell stack; and the mixed gas supply chamber, the water supply chamber, and the oxygen-containing gas supply chamber are provided at another end side distant from the fuel cell stack.
 4. The fuel cell module according to claim 1, wherein the exhaust gas combustor is provided at one end side adjacent to the fuel cell stack; and the start-up combustor is provided at another end side distant from the fuel cell stack.
 5. The fuel cell module according to claim 4, wherein a bottom surface of the combustion cup member is provided at a position deviated from an intermediate position of the first area toward the fuel cell stack.
 6. The fuel cell module according to claim 4, wherein a bottom surface of the combustion cup member is provided at a position deviated from an intermediate position of the first area away from the fuel cell stack.
 7. The fuel cell module according to claim 4, wherein the combustion cup member includes: a support portion fixed to the first area; and a cup portion attached to the support portion in an orientation from the fuel cell stack toward the first area.
 8. The fuel cell module according to claim 7, further including a fixing mechanism for fixing the support portion and the cup portion together such that the support portion and the cup portion are not rotatable with each other, the fixing mechanism being provided on the support portion and the cup portion, wherein the fixing mechanism includes a protrusion and a recess that are engaged with each other, and at least the recess is provided at a plurality of positions for enabling adjustment of a phase between the support portion and the cup portion.
 9. The fuel cell module according to claim 1, wherein the combustion gas first flows from the first area to the second area, next flows from the second area to the third area, and then the combustion gas is discharged to outside of the fuel cell module.
 10. The fuel cell module according to claim 1, wherein the fuel cell module is a solid oxide fuel cell module. 